Method for making semiconductor device comprising a superlattice with upper portions extending above adjacent upper portions of source and drain regions

ABSTRACT

A method for making a semiconductor device may include providing a semiconductor substrate and forming at least one MOSFET by forming spaced apart source and drain regions and a superlattice on the substrate so that the superlattice is between the source and drain regions. The superlattice may include a plurality of stacked groups of layers. The superlattice may have upper portions extending above adjacent upper portions of the source and drain regions, and lower portions contacting the source and drain regions so that a channel is defined in lower portions of the superlattice. Each group of layers of the superlattice may include a plurality of stacked base semiconductor monolayers defining a base semiconductor portion and an energy band-modifying layer thereon. The energy-band modifying layer may include at least one non-semiconductor monolayer constrained within a crystal lattice of adjacent base semiconductor. The method may further include forming a gate overlying the superlattice.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/647,069 filed Aug. 22, 2003, now U.S. Pat. No. 6,897,472which in turn is a continuation-in-part of U.S. patent application Ser.Nos. 10/603,696 now abandoned and 10/603,621, now abandoned both filedon Jun. 26, 2003, the entire disclosures of which are herebyincorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to the field of semiconductors, and, moreparticularly, to semiconductors having enhanced properties based uponenergy band engineering and associated methods.

BACKGROUND OF THE INVENTION

Structures and techniques have been proposed to enhance the performanceof semiconductor devices, such as by enhancing the mobility of thecharge carriers. For example, U.S. Patent Application No. 2003/0057416to Currie et al. discloses strained material layers of silicon,silicon-germanium, and relaxed silicon and also including impurity-freezones that would otherwise cause performance degradation. The resultingbiaxial strain in the upper silicon layer alters the carrier mobilitiesenabling higher speed and/or lower power devices. Published U.S. PatentApplication No. 2003/0034529 to Fitzgerald et al. discloses a CMOSinverter also based upon similar strained silicon technology.

U.S. Pat. No. 6,472,685 B2 to Takagi discloses a semiconductor deviceincluding a silicon and carbon layer sandwiched between silicon layersso that the conduction band and valence band of the second silicon layerreceive a tensile strain. Electrons having a smaller effective mass, andwhich have been induced by an electric field applied to the gateelectrode, are confined in the second silicon layer, thus, an n-channelMOSFET is asserted to have a higher mobility.

U.S. Pat. No. 4,937,204 to Ishibashi et al. discloses a superlattice inwhich a plurality of layers, less than eight monolayers, and containinga fraction or a binary compound semiconductor layers, are alternatelyand epitaxially grown. The direction of main current flow isperpendicular to the layers of the superlattice.

U.S. Pat. No. 5,357,119 to Wang et al. discloses a Si—Ge short periodsuperlattice with higher mobility achieved by reducing alloy scatteringin the superlattice. Along these lines, U.S. Pat. No. 5,683,934 toCandelaria discloses an enhanced mobility MOSFET including a channellayer comprising an alloy of silicon and a second materialsubstitutionally present in the silicon lattice at a percentage thatplaces the channel layer under tensile stress.

U.S. Pat. No. 5,216,262 to Tsu discloses a quantum well structurecomprising two barrier regions and a thin epitaxially grownsemiconductor layer sandwiched between the barriers. Each barrier regionconsists of alternate layers of SiO₂/Si with a thickness generally in arange of two to six monolayers. A much thicker section of silicon issandwiched between the barriers.

An article entitled “Phenomena in silicon nanostructure devices” also toTsu and published online Sep. 6, 2000 by Applied Physics and MaterialsScience & Processing, pp. 391-402 discloses a semiconductor-atomicsuperlattice (SAS) of silicon and oxygen. The Si/O superlattice isdisclosed as useful in a silicon quantum and light-emitting devices. Inparticular, a green electroluminescence diode structure was constructedand tested. Current flow in the diode structure is vertical, that is,perpendicular to the layers of the SAS. The disclosed SAS may includesemiconductor layers separated by adsorbed species such as oxygen atoms,and CO molecules. The silicon growth beyond the adsorbed monolayer ofoxygen is described as epitaxial with a fairly low defect density. OneSAS structure included a 1.1 nm thick silicon portion that is abouteight atomic layers of silicon, and another structure had twice thisthickness of silicon. An article to Luo et al. entitled “Chemical Designof Direct-Gap Light-Emitting Silicon” published in Physical ReviewLetters, Vol. 89, No. 7 (Aug. 12, 2002) further discusses the lightemitting SAS structures of Tsu.

Another example of an optical device incorporating a superlattice isdisclosed in U.S. Pat. No. 6,566,679 to Nikonov et al. This patentdiscloses an integrated semiconductor optical modulator which includes asemiconductor substrate and associated integrated circuit element. Theintegrated circuit element includes a superlattice having alternatinglayers of the semiconductor material and an insulator. The semiconductorlayers and insulator layers are configured to cause direct bandgapabsorption of radiation energy in the semiconductor layers to modulate aradiation beam that passes through the superlattice structure.

Published International Application WO 02/103,767 A1 to Wang, Tsu andLofgren, discloses a barrier building block of thin silicon and oxygen,carbon, nitrogen, phosphorous, antimony, arsenic or hydrogen to therebyreduce current flowing vertically through the lattice more than fourorders of magnitude. The insulating layer/barrier layer allows for lowdefect epitaxial silicon to be deposited next to the insulating layer.

Published Great Britain Patent Application 2,347,520 to Mears et al.discloses that principles of Aperiodic Photonic Band-Gap (APBG)structures may be adapted for electronic bandgap engineering. Inparticular, the application discloses that material parameters, forexample, the location of band minima, effective mass, etc, can betailored to yield new aperiodic materials with desirable band-structurecharacteristics. Other parameters, such as electrical conductivity,thermal conductivity and dielectric permittivity or magneticpermeability are disclosed as also possible to be designed into thematerial.

Despite considerable efforts at materials engineering to increase themobility of charge carriers in semiconductor devices, there is still aneed for greater improvements. Greater mobility may increase devicespeed and/or reduce device power consumption. With greater mobility,device performance can also be maintained despite the continued shift tosmaller device features.

SUMMARY OF THE INVENTION

In view of the foregoing background, it is therefore an object of thepresent invention to provide a method for making a semiconductor deviceincluding one or more MOSFETS having relatively high charge carriermobility and related methods.

This and other objects, features, and advantages in accordance with thepresent invention are provided by a method for making a semiconductordevice which may include providing a semiconductor substrate and formingat least one metal oxide semiconductor field-effect transistor (MOSFET).More particularly, the MOSFET may be formed by forming spaced apartsource and drain regions and a superlattice on the semiconductorsubstrate so that the superlattice is between the source and drainregions. The superlattice may include a plurality of stacked groups oflayers. Further, the superlattice may have upper portions extendingabove adjacent upper portions of the source and drain regions, and lowerportions contacting the source and drain regions so that a channel isdefined in lower portions of the superlattice. Also, each group oflayers of the superlattice may include a plurality of stacked basesemiconductor monolayers defining a base semiconductor portion and anenergy band-modifying layer thereon. The energy-band modifying layer mayinclude at least one non-semiconductor monolayer constrained within acrystal lattice of adjacent base semiconductor. The method may furtherinclude forming a gate overlying the superlattice.

More specifically, the source and drain regions may each include arespective epitaxial silicon layer, and the superlattice may have agreater thickness than the epitaxial silicon layers. Also, the sourceand drain regions may each have a respective trench therein adjacent thesuperlattice, and the upper portions of the superlattice may extendabove bottom portions of the trenches. The gate may include an oxidelayer overlying the superlattice channel and a gate electrode overlyingthe oxide layer. Further, a contact layer may be on the source regionsand/or the drain region.

Furthermore, the superlattice channel may have a common energy bandstructure therein, and it may also have a higher charge carrier mobilitythan would otherwise be present. Each base semiconductor portion maycomprise silicon or germanium, for example, and each energyband-modifying layer may comprise oxygen. Further, each energyband-modifying layer may be a single monolayer thick, and each basesemiconductor portion may be less than eight monolayers thick.

The superlattice may further have a substantially direct energy bandgap,and it may also include a base semiconductor cap layer on an uppermostgroup of layers. In one embodiment, all of the base semiconductorportions may be a same number of monolayers thick. In accordance with analternate embodiment, at least some of the base semiconductor portionsmay be a different number of monolayers thick. In addition, each energyband-modifying layer may include a non-semiconductor selected from thegroup consisting of oxygen, nitrogen, fluorine, and carbon-oxygen, forexample.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic cross-sectional view of a semiconductor device inaccordance with the present invention.

FIG. 2 is a greatly enlarged schematic cross-sectional view of thesuperlattice as shown in FIG. 1.

FIG. 3 is a perspective schematic atomic diagram of a portion of thesuperlattice shown in FIG. 1.

FIG. 4 is a greatly enlarged schematic cross-sectional view of anotherembodiment of a superlattice that may be used in the device of FIG. 1.

FIG. 5A is a graph of the calculated band structure from the gamma point(G) for both bulk silicon as in the prior art, and for the 4/1 Si/Osuperlattice as shown in FIGS. 1-3.

FIG. 5B is a graph of the calculated band structure from the Z point forboth bulk silicon as in the prior art, and for the 4/1 Si/O superlatticeas shown in FIGS. 1-3.

FIG. 5C is a graph of the calculated band structure from both the gammaand Z points for both bulk silicon as in the prior art, and for the5/1/3/1 Si/O superlattice as shown in FIG. 4.

FIGS. 6A-6E are a series of schematic cross-sectional diagramsillustrating a method for making the semiconductor device of FIG. 1.

FIGS. 7A-7E are a series of schematic cross-sectional diagramsillustrating a method for making an alternate embodiment of thesemiconductor device of FIG. 1.

FIG. 8 is a schematic cross-sectional diagram illustrating a completedsemiconductor device formed using the method steps illustrated in FIGS.7A-7E.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout, and prime and multiple primenotation are used to indicate similar elements in alternate embodiments.

The present invention relates to controlling the properties ofsemiconductor materials at the atomic or molecular level to achieveimproved performance within semiconductor devices. Further, theinvention relates to the identification, creation, and use of improvedmaterials for use in the conduction paths of semiconductor devices.

Applicants theorize, without wishing to be bound thereto, that certainsuperlattices as described herein reduce the effective mass of chargecarriers and that this thereby leads to higher charge carrier mobility.Effective mass is described with various definitions in the literature.As a measure of the improvement in effective mass Applicants use a“conductivity reciprocal effective mass tensor”, M_(e) ⁻¹ and M_(h) ⁻¹for electrons and holes respectively, defined as:

${M_{e,{ij}}^{- 1}( {E_{F},T} )} = \frac{\sum\limits_{E > E_{F}}^{\;}\;{{\int\limits_{B.Z.}}^{\;}{( {\nabla_{k}{E( {k,n} )}} )_{i}( {\nabla_{k}{E( {k,n} )}} )_{j}\ \frac{\partial{f( {{E( {k,n} )},E_{F},T} )}}{\partial E}{\mathbb{d}^{3}k}}}}{\sum\limits_{E > E_{F}}^{\;}\;{{\int\limits_{B.Z.}}^{\;}{{f( {{E( {k,n} )},E_{F},T} )}d^{3}k}}}$for electrons and:

${M_{h,{ij}}^{- 1}( {E_{F},T} )} = \frac{- {\sum\limits_{E < E_{F}}^{\;}\;{{\int\limits_{B.Z.}}^{\;}{( {\nabla_{k}{E( {k,n} )}} )_{i}( {\nabla_{k}{E( {k,n} )}} )_{j}\ \frac{\partial{f( {{E( {k,n} )},E_{F},T} )}}{\partial E}{\mathbb{d}^{3}k}}}}}{\sum\limits_{E < E_{F}}^{\;}\;{\int\limits_{B.Z.}( {1 -^{\;}{{f( {{E( {k,n} )},E_{F},T} )}d^{3}k}} }}$for holes, where f is the Fermi-Dirac distribution, E_(F) is the Fermienergy, T is the temperature, E(k,n) is the energy of an electron in thestate corresponding to wave vector k and the n^(th) energy band, theindices i and j refer to Cartesian coordinates x, y and z, the integralsare taken over the Brillouin zone (B.Z.), and the summations are takenover bands with energies above and below the Fermi energy for electronsand holes respectively.

Applicants' definition of the conductivity reciprocal effective masstensor is such that a tensorial component of the conductivity of thematerial is greater for greater values of the corresponding component ofthe conductivity reciprocal effective mass tensor. Again Applicantstheorize without wishing to be bound thereto that the superlatticesdescribed herein set the values of the conductivity reciprocal effectivemass tensor so as to enhance the conductive properties of the material,such as typically for a preferred direction of charge carrier transport.The inverse of the appropriate tensor element is referred to as theconductivity effective mass. In other words, to characterizesemiconductor material structures, the conductivity effective mass forelectrons/holes as described above and calculated in the direction ofintended carrier transport is used to distinguish improved materials.

Using the above-described measures, one can select materials havingimproved band structures for specific purposes. One such example wouldbe a superlattice 25 material for a channel region in a semiconductordevice. A planar MOSFET 20 including the superlattice 25 in accordancewith the invention is now first described with reference to FIG. 1. Oneskilled in the art, however, will appreciate that the materialsidentified herein could be used in many different types of semiconductordevices, such as discrete devices and/or integrated circuits.

The illustrated MOSFET 20 includes a substrate 21, source and drainregions 22, 23, and the superlattice 25 is positioned between the sourceand drain regions. In the illustrated example, the source and drainregions 22, 23 are raised source and drain regions in that they includerespective epitaxial silicon layers 26, 28 formed on the substrate 21which are doped to the desired concentration. Moreover, the dopant maypermeate portions 27, 29 of the substrate 21 so that the source anddrain regions 22, 23 extend beneath the epitaxial layers 26, 28,respectively, and under the superlattice 25, as shown.

The MOSFET 20 also illustratively includes a gate 35 comprising a gateinsulating (e.g., oxide) layer 37 on the superlattice 25 and a gateelectrode layer 36 on the gate insulating layer. Source/drain silicidelayers 30, 31 and source/drain contacts 32, 33 overlie the source/drainregions, as will be appreciated by those skilled in the art.

In the illustrated embodiment, upper portions of the superlattice 25extend above adjacent upper portions of the source and drain regions 22,23, and, more particularly, the epitaxial layers 26, 28. Statedalternately, the superlattice 25 has a greater thickness than theepitaxial layers 26, 28, and thus upper sidewall portions of thesuperlattice do not contact the epitaxial layers. Yet, lower sidewallportions of the superlattice 25 do contact the source and drain regions22, 23 as shown so that a channel is defined in lower portions of thesuperlattice.

Accordingly, it will be appreciated by those skilled in the art that thechannel only occupies the lower portion of the superlattice 25, and thuscurrent flow is reduced in the upper portions of the superlattice nearthe gate insulating layer 37. This advantageously reduces hot carrierinjection, for example, which may otherwise result in premature oxidebreakdown and failure, as will be appreciated by those skilled in theart.

Applicants have identified improved materials or structures for thesuperlattice 25 of the MOSFET 20. More specifically, the Applicants haveidentified materials or structures having energy band structures forwhich the appropriate conductivity effective masses for electrons and/orholes are substantially less than the corresponding values for silicon.

Referring now additionally to FIGS. 2 and 3, the materials or structuresare in the form of a superlattice 25 whose structure is controlled atthe atomic or molecular level and may be formed using known techniquesof atomic or molecular layer deposition. The superlattice 25 includes aplurality of layer groups 45 a- 45 n arranged in stacked relation, asperhaps best understood with specific reference to the schematiccross-sectional view of FIG. 2.

Each group of layers 45 a-45 n of the superlattice 25 illustrativelyincludes a plurality of stacked base semiconductor monolayers 46defining a respective base semiconductor portion 46 a-46 n and an energyband-modifying layer 50 thereon. The energy band-modifying layers 50 areindicated by stippling in FIG. 2 for clarity of illustration.

The energy-band modifying layer 50 illustratively includes onenon-semiconductor monolayer constrained within a crystal lattice ofadjacent base semiconductor portions. In other embodiments, more thanone such monolayer may be possible. It should be noted that referenceherein to a non-semiconductor or semiconductor monolayer means that thematerial used for the monolayer would be a non-semiconductor orsemiconductor if formed in bulk. That is, a single monolayer of amaterial, such as semiconductor, may not necessarily exhibit the sameproperties that it would if formed in bulk or in a relatively thicklayer, as will be appreciated by those skilled in the art.

Applicants theorize without wishing to be bound thereto that the energyband-modifying layers 50 and adjacent base semiconductor portions 46a-46 n cause the superlattice 25 to have a lower appropriateconductivity effective mass for the charge carriers in the parallellayer direction than would otherwise be present. Considered another way,this parallel direction is orthogonal to the stacking direction. Theband modifying layers 50 may also cause the superlattice 25 to have acommon energy band structure.

It is also theorized that the semiconductor device, such as theillustrated MOSFET 20, enjoys a higher charge carrier mobility basedupon the lower conductivity effective mass than would otherwise bepresent. In some embodiments, and as a result of the band engineeringachieved by the present invention, the superlattice 25 may further havea substantially direct energy bandgap that may be particularlyadvantageous for opto-electronic devices, for example, as described infurther detail below.

As will be appreciated by those skilled in the art, the source/drainregions 22, 23 and gate 35 of the MOSFET 20 may be considered as regionsfor causing the transport of charge carriers through the superlattice ina parallel direction relative to the layers of the stacked groups 45a-45 n. Other such regions are also contemplated by the presentinvention.

The superlattice 25 also illustratively includes a cap layer 52 on anupper layer group 45 n. The cap layer 52 may comprise a plurality ofbase semiconductor monolayers 46. The cap layer 52 may have between 2 to100 monolayers of the base semiconductor, and, more preferably between10 to 50 monolayers.

Each base semiconductor portion 46 a-46 n may comprise a basesemiconductor selected from the group consisting of Group IVsemiconductors, Group III-V semiconductors, and Group II-VIsemiconductors. Of course, the term Group IV semiconductors alsoincludes Group IV-IV semiconductors, as will be appreciated by thoseskilled in the art. More particularly, the base semiconductor maycomprise at least one of silicon and germanium, for example.

Each energy band-modifying layer 50 may comprise a non-semiconductorselected from the group consisting of oxygen, nitrogen, fluorine, andcarbon-oxygen, for example. The non-semiconductor is also desirablythermally stable through deposition of a next layer to therebyfacilitate manufacturing. In other embodiments, the non-semiconductormay be another inorganic or organic element or compound that iscompatible with the given semiconductor processing, as will beappreciated by those skilled in the art.

It should be noted that the term monolayer is meant to include a singleatomic layer and also a single molecular layer. It is also noted thatthe energy band-modifying layer 50 provided by a single monolayer isalso meant to include a monolayer wherein not all of the possible sitesare occupied. For example, with particular reference to the atomicdiagram of FIG. 3, a 4/1 repeating structure is illustrated for siliconas the base semiconductor material, and oxygen as the energyband-modifying material. Only half of the possible sites for oxygen areoccupied.

In other embodiments and/or with different materials this one halfoccupation would not necessarily be the case as will be appreciated bythose skilled in the art. Indeed, it can be seen even in this schematicdiagram, that individual atoms of oxygen in a given monolayer are notprecisely aligned along a flat plane as will also be appreciated bythose of skill in the art of atomic deposition. By way of example, apreferred occupation range is from about one-eighth to one-half of thepossible oxygen sites being full, although other numbers may be used incertain embodiments.

Silicon and oxygen are currently widely used in conventionalsemiconductor processing, and, hence, manufacturers will be readily ableto use these materials as described herein. Atomic or monolayerdeposition is also now widely used. Accordingly, semiconductor devicesincorporating the superlattice 25 in accordance with the invention maybe readily adopted and implemented, as will be appreciated by thoseskilled in the art.

It is theorized without Applicants wishing to be bound thereto that fora superlattice, such as the Si/O superlattice, for example, that thenumber of silicon monolayers should desirably be seven or less so thatthe energy band of the superlattice is common or relatively uniformthroughout to achieve the desired advantages. The 4/1 repeatingstructure shown in FIGS. 2 and 3 for Si/O has been modeled to indicatean enhanced mobility for electrons and holes in the X direction. Forexample, the calculated conductivity effective mass for electrons(isotropic for bulk silicon) is 0.26 and for the 4/1 SiO superlattice inthe X direction it is 0.12, resulting in a ratio of 0.46. Similarly, thecalculation for holes yields values of 0.36 for bulk silicon and 0.16for the 4/1 Si/O superlattice resulting in a ratio of 0.44.

While such a directionally preferential feature may be desired incertain semiconductor devices, other devices may benefit from a moreuniform increase in mobility in any direction parallel to the groups oflayers. It may also be beneficial to have an increased mobility for bothelectrons and holes, or just one of these types of charge carriers, aswill be appreciated by those skilled in the art.

The lower conductivity effective mass for the 4/1 Si/O embodiment of thesuperlattice 25 may be less than two-thirds the conductivity effectivemass than would otherwise occur, and this applies for both electrons andholes. Of course, the superlattice 25 may further comprise at least onetype of conductivity dopant therein as will also be appreciated by thoseskilled in the art.

Indeed, referring now additionally to FIG. 4, another embodiment of asuperlattice 25′ in accordance with the invention having differentproperties is now described. In this embodiment, a repeating pattern of3/1/5/1 is illustrated. More particularly, the lowest base semiconductorportion 46 a′ has three monolayers, and the second lowest basesemiconductor portion 46 b′ has five monolayers. This pattern repeatsthroughout the superlattice 25′. The energy band-modifying layers 50′may each include a single monolayer. For such a superlattice 25′including Si/O, the enhancement of charge carrier mobility isindependent of orientation in the plane of the layers. Those otherelements of FIG. 4 not specifically mentioned are similar to thosediscussed above with reference to FIG. 2 and need no further discussionherein.

In some device embodiments, all of the base semiconductor portions of asuperlattice may be a same number of monolayers thick. In otherembodiments, at least some of the base semiconductor portions may be adifferent number of monolayers thick. In still other embodiments, all ofthe base semiconductor portions may be a different number of monolayersthick.

In FIGS. 5A-5C band structures calculated using Density FunctionalTheory (DFT) are presented. It is well known in the art that DFTunderestimates the absolute value of the bandgap. Hence all bands abovethe gap may be shifted by an appropriate “scissors correction.” Howeverthe shape of the band is known to be much more reliable. The verticalenergy axes should be interpreted in this light.

FIG. 5A shows the calculated band structure from the gamma point (G) forboth bulk silicon (represented by continuous lines) and for the 4/1 Si/Osuperlattice 25 as shown in FIGS. 1-3 (represented by dotted lines). Thedirections refer to the unit cell of the 4/1 Si/O structure and not tothe conventional unit cell of Si, although the (001) direction in thefigure does correspond to the (001) direction of the conventional unitcell of Si, and, hence, shows the expected location of the Si conductionband minimum. The (100) and (010) directions in the figure correspond tothe (110) and (−110) directions of the conventional Si unit cell. Thoseskilled in the art will appreciate that the bands of Si on the figureare folded to represent them on the appropriate reciprocal latticedirections for the 4/1 Si/O structure.

It can be seen that the conduction band minimum for the 4/1 Si/Ostructure is located at the gamma point in contrast to bulk silicon(Si), whereas the valence band minimum occurs at the edge of theBrillouin zone in the (001) direction which we refer to as the Z point.One may also note the greater curvature of the conduction band minimumfor the 4/1 Si/O structure compared to the curvature of the conductionband minimum for Si owing to the band splitting due to the perturbationintroduced by the additional oxygen layer.

FIG. 5B shows the calculated band structure from the Z point for bothbulk silicon (continuous lines) and for the 4/1 Si/O superlattice 25(dotted lines). This figure illustrates the enhanced curvature of thevalence band in the (100) direction.

FIG. 5C shows the calculated band structure from both the gamma and Zpoint for both bulk silicon (continuous lines) and for the 5/1/3/1 Si/Ostructure of the superlattice 25′ of FIG. 4 (dotted lines). Due to thesymmetry of the 5/1/3/1 Si/O structure, the calculated band structuresin the (100) and (010) directions are equivalent. Thus the conductivityeffective mass and mobility are expected to be isotropic in the planeparallel to the layers, i.e., perpendicular to the (001) stackingdirection. Note that in the 5/1/3/1 Si/O example the conduction bandminimum and the valence band maximum are both at or close to the Zpoint.

Although increased curvature is an indication of reduced effective mass,the appropriate comparison and discrimination may be made via theconductivity reciprocal effective mass tensor calculation. This leadsApplicants to further theorize that the 5/1/3/1 superlattice 25′ shouldbe substantially direct bandgap. As will be understood by those skilledin the art, the appropriate matrix element for optical transition isanother indicator of the distinction between direct and indirect bandgapbehavior.

Referring now additionally to FIGS. 6A-6E, a method for making theMOSFET 20 will now be described. The method begins with providing thesilicon substrate 21. By way of example, the substrate may be aneight-inch wafer 21 of lightly doped P-type or N-type single crystalsilicon with <100> orientation, although other suitable substrates mayalso be used. In accordance with the present example, a layer of thesuperlattice 25 material is then formed across the upper surface of thesubstrate 21.

More particularly, the superlattice 25 material is deposited across thesurface of the substrate 21 using atomic layer deposition and theepitaxial silicon cap layer 52 is formed, as discussed previously above,and the surface is planarized to arrive at the structure of FIG. 6A. Itshould be noted that in some embodiments the superlattice 25 materialmay be selectively deposited in those regions where channels are to beformed, rather than across the entire substrate 21, as will beappreciated by those skilled in the art. Moreover, planarization may notbe required in all embodiments.

The epitaxial silicon cap layer 52 may have a preferred thickness toprevent superlattice consumption during gate oxide growth, or any othersubsequent oxidations, while at the same time reducing or minimizing thethickness of the silicon cap layer to reduce any parallel path ofconduction with the superlattice. According to the well-knownrelationship of consuming approximately 45% of the underlying siliconfor a given oxide grown, the silicon cap layer may be greater than 45%of the grown gate oxide thickness plus a small incremental amount toaccount for manufacturing tolerances known to those skilled in the art.For the present example, and assuming growth of a 25 angstrom gate, onemay use approximately 13-15 angstroms of silicon cap thickness.

FIG. 6B depicts the MOSFET 20 after the gate oxide 37 and the gateelectrode 36 are formed. More particularly, a thin gate oxide isdeposited, and steps of poly deposition, patterning, and etching areperformed, as will be appreciated by those skilled in the art. Polydeposition refers to low pressure chemical vapor deposition (LPCVD) ofsilicon onto an oxide (hence it forms a polycrystalline material). Thestep includes doping with P+ or As− to make it conducting, and the layermay be around 250 nm thick, for example.

In addition, the pattern step may include performing a spinningphotoresist, baking, exposure to light (i.e., a photolithography step),and developing the resist. Usually, the pattern is then transferred toanother layer (oxide or nitride) which acts as an etch mask during theetch step. The etch step typically is a plasma etch (anisotropic, dryetch) that is material selective (e.g., etches silicon ten times fasterthan oxide) and transfers the lithography pattern into the material ofinterest.

Referring to FIG. 6C, once the gate 35 is formed, the gate may then beused as an etch mask to remove the superlattice 25 material in theregions where the source and drain 22, 23 are to be formed, as will beappreciated by those skilled in the art. The superlattice 25 materialmay be etched in a similar fashion to that described above for the gate35. However, it should be noted that with the non-semiconductor presentin the superlattice 25, e.g., oxygen, the superlattice may be moreeasily etched using an etchant formulated for oxides rather thansilicon. Of course, the appropriate etch for a given implementation willvary based upon the structure and materials used for the superlattice 25and substrate 21, as will be appreciated by those of skill in the art.

In FIG. 6D, the epitaxial source and drain layers 26, 28 are formed,which may be done using known epitaxial deposition methods. Referring toFIG. 6E, the source and drain regions 22, 23 are doped using theappropriate n-type or p-type implantation. An anneal and/or clean stepmay be used after the implantation, but depending on the specificprocess, they may be omitted. Self-aligned silicide formation may thenbe performed to form the silicide layers 30, 31, and 34, and thesource/drain contacts 32, 33, are formed to provide the finalsemiconductor device 20 illustrated in FIG. 1. The silicide formation isalso known as salicidation. The salicidation process includes metaldeposition (e.g. Ti), nitrogen annealing, metal etching, and a secondannealing.

The foregoing is, of course, but one example of a process and device inwhich the present invention may be used, and those of skill in the artwill understand its application and use in many other processes anddevices. In other processes and devices the structures of the presentinvention may be formed on a portion of a wafer or across substantiallyall of a wafer. Additionally, the use of an atomic layer deposition toolmay also not be needed for forming the superlattice 25 in someembodiments. For example, the monolayers may be formed using a CVD toolwith process conditions compatible with control of monolayers, as willbe appreciated by those skilled in the art.

An alternate embodiment of the semiconductor device 20″ and method formmaking the same will now be described with reference to FIGS. 7A-7E and8. First, a trench 70″ is formed in the substrate 21″ using knownsemiconductor techniques (FIG. 7A). Next, the superlattice 25″ is formedwithin the trench 70″ (FIG. 7B), as described above. The gate insulatinglayer 37″ and gate electrode layer 36″ are then formed and patterned, asnecessary, as seen in FIG. 7C. Trenches 71″, 72″ are then formed next tothe gate in the substrate 21″ in the areas where the source and drainregions 23″, 24″ are to be formed (FIG. 7D).

Thus, it may be seen that the upper portions of the superlattice 25″extend above bottom portions 73″, 74″ of the trenches 71″, 72″. Again,this creates a channel region which occupies only the lower portions ofthe superlattice 25″, thus advantageously reducing current flow near thegate insulation layer 37″. Source and drain implantation is nextperformed, as described above, to form the source and drain regions 22″,23″ (FIG. 7E). Furthermore, silicide formation may then be performed toform the silicide layers 30″, 31″, and 34″, and the source/draincontacts 32″, 33″ are formed to provide the final semiconductor device20″ illustrated in FIG. 8.

It should be noted that certain of the above-noted steps may beperformed in different orders in different embodiments. For example, thetrenches 71″, 72″ may be formed after implantation of the source anddrain regions 22″, 23″. Moreover, in an alternate embodiment, thetrenches 71″, 72″ may be formed in the superlattice 25″ at the outeredges thereof to provide the desired separation between the upperportions of the superlattice and the source and drain regions 22″, 23″,as will be appreciated by those skilled in the art.

While only a single MOSFET 20″ has been illustrated in the drawings anddescribed above for clarity of explanation and illustration, it will beappreciated that multiple MOSFETs may be formed in the substrate 21″,such as NMOS and PMOS transistors to provide a CMOS device. Moreparticularly, shallow trench isolation (STI) regions (not shown) may beformed between adjacent MOSFETS, as will be appreciated by those skilledin the art. In accordance with one embodiment, the STI regions may beformed prior to depositing the superlattice 25″, so that the STI regionsthus provide boundaries for selective deposition of the superlattice.

More particularly, the wafer is patterned and trenches are etched (e.g.,0.3-0.8 um) in the desired STI regions. A thin oxide is then grown, andthe trenches are filled with SiO₂ to provide the STI regions, and theupper surfaces thereof may be planarized, if desired. The STI regionsmay also be used as an etch stop in performing certain of theabove-noted steps, as will be appreciated by those skilled in the art.The superlattice 25″ structure may also be formed prior to formation ofthe STI regions to thereby eliminate a masking step, if desired. Furtherdetails regarding fabrication of the semiconductor devices in accordancewith the present invention may be found in the above-noted U.S.application Ser. No. 10/467,069.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is understood that the invention is not to be limited tothe specific embodiments disclosed, and that modifications andembodiments are intended to be included within the scope of the appendedclaims.

1. A method for making a semiconductor device comprising: providing asemiconductor substrate; and forming at least one metal oxidesemiconductor field-effect transistor (MOSFET) by forming spaced apartsource and drain regions and a superlattice on the semiconductorsubstrate so that the superlattice is between the source and drainregions, the superlattice comprising a plurality of stacked groups oflayers and having upper portions extending above adjacent upper portionsof the source and drain regions and lower portions contacting the sourceand drain regions so that a channel is defined in lower portions of thesuperlattice, each group of layers of the superlattice comprising aplurality of stacked base semiconductor monolayers defining a basesemiconductor portion and an energy band-modifying layer thereon, theenergy-band modifying layer comprising at least one non-semiconductormonolayer constrained within a crystal lattice of adjacent basesemiconductor portions, and at least some semiconductor atoms fromopposing semiconductor portions being chemically bound together throughthe at least one non-semiconductor monolayer therebetween, and forming agate overlying the superlattice.
 2. The method of claim 1 wherein eachof the source and drain regions comprises a respective epitaxial siliconlayer.
 3. The method of claim 2 wherein the superlattice has a greaterthickness than the epitaxial silicon layers.
 4. The method of claim 1wherein the source and drain regions each have a respective trenchtherein adjacent the superlattice; and wherein the upper portions of thesuperlattice extend above bottom portions of the trenches.
 5. The methodof claim 1 wherein forming the gate comprises forming an oxide layeroverlying the superlattice channel and a gate electrode overlying theoxide layer.
 6. The method of claim 1 further comprising forming acontact layer on at least one of the source and drain regions.
 7. Themethod of claim 1 wherein the superlattice has a common energy bandstructure therein.
 8. The method of claim
 1. wherein the superlatticehas a higher charge carrier mobility than would otherwise be presentwithout the non-semiconductor layer.
 9. The method of claim 1 whereineach base semiconductor portion comprises silicon.
 10. The method ofclaim 1 wherein each base semiconductor portion comprises germanium. 11.The method of claim 1 wherein each energy band-modifying layer comprisesoxygen.
 12. The method of claim 1 wherein each energy band-modifyinglayer is a single monolayer thick.
 13. The method of claim 1 whereineach base semiconductor portion is less than eight monolayers thick. 14.The method of claim 1 wherein the superlattice further has asubstantially direct energy bandgap.
 15. The method of claim 1 whereinthe superlattice further comprises a base semiconductor cap layer on anuppermost group of layers.
 16. The method of claim 1 wherein all of thebase semiconductor portions are a same number of monolayers thick. 17.The method of claim 1 wherein at least some of the base semiconductorportions are a different number of monolayers thick.
 18. The method ofclaim 1 wherein each energy band-modifying layer comprises anon-semiconductor selected from the group consisting of oxygen,nitrogen, fluorine, and carbon-oxygen.
 19. A method for making asemiconductor device comprising: providing a semiconductor substrate;and forming at least one metal oxide semiconductor field-effecttransistor (MOSFET) by forming spaced apart source and drain regions anda superlattice on the semiconductor substrate so that the superlatticeis between the source and drain regions, the source and drain regionseach having a respective trench therein adjacent the superlattice, andthe superlattice having upper portions extending above bottom portionsof the trenches and lower portions contacting the source and drainregions so that a channel is defined in lower portions of thesuperlattice, each group of layers of the superlattice comprising aplurality of stacked base semiconductor monolayers defining a basesemiconductor portion and an energy band-modifying layer thereon, theenergy-band modifying layer comprising at least one non-semiconductormonolayer constrained within a crystal lattice of adjacent basesemiconductor, and at least some semiconductor atoms from opposingsemiconductor portions being chemically bound together through the atleast one non-semiconductor monolayer therebetween, and forming a gateoverlying the superlattice by forming an oxide layer overlying thesuperlattice channel and a gate electrode overlying the oxide layer. 20.The method of claim 19 further comprising forming a contact layer on atleast one of the source and drain regions.
 21. The method of claim 19wherein the superlattice has a common energy band structure therein. 22.The method of claim 19 wherein the superlattice has a higher chargecarrier mobility than would otherwise be present without thenon-semiconductor layer.
 23. The method of claim 19 wherein each basesemiconductor portion comprises silicon.
 24. The method of claim 19wherein each base semiconductor portion comprises germanium.
 25. Themethod of claim 19 wherein each energy band-modifying layer comprisesoxygen.
 26. The method of claim 19 wherein each energy band-modifyinglayer is a single monolayer thick.
 27. The method of claim 19 whereineach base semiconductor portion is less than eight monolayers thick. 28.The method of claim 19 wherein the superlattice further has asubstantially direct energy bandgap.
 29. The method of claim 19 whereinthe superlattice further comprises a base semiconductor cap layer on anuppermost group of layers.
 30. The method of claim 19 wherein all of thebase semiconductor portions are a same number of monolayers thick. 31.The method of claim 19 wherein at least some of the base semiconductorportions are a different number of monolayers thick.
 32. The method ofclaim 19 wherein each energy band-modifying layer comprises anon-semiconductor selected from the group consisting of oxygen,nitrogen, fluorine, and carbon-oxygen.
 33. A method for making asemiconductor device comprising: providing a semiconductor substrate;and forming at least one metal oxide semiconductor field-effecttransistor (MOSFET) by forming spaced apart source and drain regions anda superlattice on the semiconductor substrate so that the superlatticeis between the source and drain regions, the source and drain regionseach comprising a respective epitaxial silicon layer, and thesuperlattice comprising a plurality of stacked groups of layers, thesuperlattice having a greater thickness than the epitaxial siliconlayers, and lower portions of the superlattice being in contact with theepitaxial silicon layers so that a channel is defined in lower portionsof the superlattice, each group of layers of the superlattice comprisinga plurality of stacked base semiconductor monolayers defining a basesemiconductor portion and an energy band-modifying layer thereon, theenergy-band modifying layer comprising at least one non-semiconductormonolayer constrained within a crystal lattice of adjacent basesemiconductor portions, and at least some semiconductor atoms fromopposing semiconductor portions being chemically bound together throughthe at least one non-semiconductor monolayer therebetween, and forming agate overlying the superlattice by forming an oxide layer overlying thesuperlattice channel and a gate electrode overlying the oxide layer. 34.The method of claim 33 further comprising forming a contact layer on atleast one of the source and drain regions.
 35. The method of claim 33wherein the superlattice has a common energy band structure therein. 36.The method of claim 33 wherein the superlattice has a higher chargecarrier mobility than would otherwise be present without thenon-semiconductor layer.
 37. The method of claim 33 wherein each basesemiconductor portion comprises silicon.
 38. The method of claim 33wherein each base semiconductor portion comprises germanium.
 39. Themethod of claim 33 wherein each energy band-modifying layer comprisesoxygen.
 40. The method of claim 33 wherein each energy band-modifyinglayer is a single monolayer thick.
 41. The method of claim 33 whereineach base semiconductor portion is less than eight monolayers thick. 42.The method of claim 33 wherein the superlattice further has asubstantially direct energy bandgap.
 43. The method of claim 33 whereinthe superlattice further comprises a base semiconductor cap layer on anuppermost group of layers.
 44. The method of claim 33 wherein all of thebase semiconductor portions are a same number of monolayers thick. 45.The method of claim 33 wherein at least some of the base semiconductorportions are a different number of monolayers thick.
 46. The method ofclaim 33 wherein each energy band-modifying layer comprises anon-semiconductor selected from the group consisting of oxygen,nitrogen, fluorine, and carbon-oxygen.